Overflow assembly for bathtubs and the like

ABSTRACT

An overflow system in the bathtub has an overflow port and has a drain pipe in connection with the overflow port. A threaded flange has a stub shoulder on one end which is fitted into a circular sleeve on the overflow port. The threaded flange has exterior threads on its outer surface and a thin diaphragm secured to the end thereof opposite to the stub shoulder. A large sealing washer embraces the outside of the circular flange on the overflow port and extends partially over the threads of the threaded flange. A large internally threaded nut is threadably mounted on the outer end of the threaded flange and compresses the sealing washer against a vertical flange on the port to seal the connection between the threaded flange and the port. A decorative cap is frictionally snapped into engagement with protrusions on the outer surface of the nut. The cap can be removed when needed to permit the plumber to gain access to the diaphragm to cut it open for fluid flow after the system has been tested for leaks, or put in place after the cut takes place.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. patent applicationSer. No. 10/674,862 filed Sep. 30, 2003 which is a continuation of U.S.patent application Ser. No. 10/222,062, now U.S. Pat. No. 6,637,050, andU.S. patent application Ser. No. 10/229,533 filed Aug. 28, 2002.

BACKGROUND OF THE INVENTION

[0002] In new building construction, the plumbers prefer not to put thefinished closure valves in the bottom of tubs, or the finisheddecorative plate over the overflow outlet at the end, of the tub untilthe project is finished because these elements will be often damaged asthe construction project is brought to a close. Further, the piping forboth of the outlets needs to be checked for leaks before the inspectionprocess is completed. The test involves running water down the vent forthe drain until it reaches a level above the tub and the tester thendetermines whether any of the piping leaks. Thus, when the testingoperation arrives, a plug is put in the bottom drain of the tub and somesort of seal plate is placed at the end of the tub on the overflowoutlet.

[0003] Existing overflow plates have a center opening therein. There areeither two or four small screw holes in the plate adjacent the centeropening wherein two of the holes are used to hold the plate to theplumbing fixture. In some cases there is a fitting so that the screwhole is located directly in the middle of the access hole. In that case,that hole is in the way when the testing procedure is implemented. Inany event, the testing procedure usually involves stuffing a balloonthrough the large center opening into the pipe in the wall and the pipeis sealed when the balloon is inflated. Further, existing seal platesnormally have to be removed when the decorative plate is put on. Twoscrews which use the screw openings of the plate typically hold thedecorative plate in position.

[0004] A more recent version is shown in the U.S. Pat. No. 5,890,241 inwhich an overflow system for a bathtub has an overflow port and has adrain pipe in connection with the overflow port. A flexible diaphragm isimposed over overflow drain pipe secured to and engages the inner faceof the sleeve. Screws extend through the plate which has a centeropening. A screw extends through the plate to hold the cap in place. Thecap has a conventional side rim extending around the plate anddiaphragm. A cut-out portion of the cap provides for water flow. Thediaphragm seals the overflow pipe when the system is being tested forleaks with pressurized fluid. Following the tests, when the fluid isremoved, the diaphragm is cut or slashed to open the overflow port toprovide fluid flow. While this device serves the intended function, itis expensive to make and more cumbersome to assemble.

[0005] It is, therefore, a principal object of the invention to providea method and a means for an overflow assembly for bathtubs and the likewhich will safeguard the overflow system during construction; preparethe system for testing; and facilitate the final installation of thebathtub hardware.

[0006] A further object of the invention is to facilitate the testingprocedure of the overflow system before the final installation has takenplace, and to permit the assembly of parts without the use of screws,screw holes, and the like.

[0007] It is further an object of this invention to provide an overflowfitting which will safeguard the overflow system during construction.

[0008] A further object of the invention is to provide an overflowfitting which will prepare the overflow system for testing.

[0009] A still further object of the invention is to provide an overflowfitting which allows a user to install the overflow fitting withoutusing solvent cement.

[0010] These and other objects will be apparent to those skilled in theart.

SUMMARY OF THE INVENTION

[0011] An overflow system in the bathtub has an overflow port and has adrain pipe in connection with the overflow port. A threaded flange has astub shoulder on one end which is fitted into a circular sleeve on theoverflow port. The threaded flange has exterior threads on its outersurface and a thin diaphragm secured to the end thereof opposite to thestub shoulder. A large sealing washer embraces the outside of thecircular flange on the overflow port and extends partially over thethreads of the threaded flange. A large internally threaded nut isthreadably mounted on the outer end of the threaded flange andcompresses the sealing washer against a vertical flange on the port toseal the connection between the threaded flange and the port. Adecorative cap is frictionally snapped into engagement with protrusionson the outer surfaces of the nut. The cap can be removed if needed topermit the plumber to gain access to the diaphragm to cut it open forfluid flow after the system has been tested for leaks, or put in placeafter the cut takes place.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a partial perspective view of a conventional bathtubenvironment utilizing the invention of this application;

[0013]FIG. 2 is a large scale section view taken on line 2-2 of FIG. 1;

[0014]FIG. 3 is a perspective exploded view of the cap, nut, washer,membrane, and upper pipe;

[0015]FIG. 4 is a cross sectional view of the assembled components ofFIG. 3;

[0016]FIG. 5 is a perspective view showing the piercing of the Membrane;

[0017]FIG. 6 is a sectional side view of a conventional bathtubenvironment utilizing the device of this invention;

[0018]FIG. 7 is a side view of the device of this invention;

[0019]FIG. 8 is a front view of the device of this invention;

[0020]FIG. 9 is an exploded perspective view of the device of thisinvention; and

[0021]FIG. 10 is a perspective view of the installation of the device ofthis invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0022] With reference of FIGS. 1 and 2, a conventional bathroomstructure 10 has a floor 12, and a hollow wall 14 with a wall opening 16therein. A conventional bathtub (“tub”) 18 has a base 20 which restsupon floor 12. Sidewalls 22 extend upwardly from base 20 as does an endwall 24. The end walls 24 extend upwardly from the bottom 26,perpendicular to the side walls 22, and have an outer surface. A bottom26 dwells in spaced relation to the floor 12.

[0023] A conventional drain port 28 is located in bottom 26. Aconventional overflow port 30 is located in the end wall 24 1 (FIG. 2).A vertical drain pipe 32 extends downwardly from drain port 28, andoverflow drain pipe 34 extends downwardly from overflow port 30. Ahorizontal pipe 36 connects pipes 32 and 34. A drain pipe 38 extendsdownwardly from the junction between pipes 34 and 36.

[0024] A conventional vertical vent pipe 40 is located within the hollowwall 14. Pipe 42 interconnects vent pipe 40 and the upper end ofoverflow drain pipe 34 (FIG. 2). Conventional water pipes 44 extendthrough hollow wall 14 and are connected to valve 46 which isinterconnected to conventional control member 48 and faucet 50.

[0025]FIG. 3 shows a radial flange 52 formed on the upper end of pipe 34and has a center opening or port 54. Water can flow through centeropening 54 into drain pipe 34. Sleeve 56 extends longitudinallyoutwardly from the perimeter of opening 54 forming a surface on itsinner diameter.

[0026] A hollow cylindrical fitting 58 has a hollow cylindrical shoulder60 on its inner end, a threaded outer surface 62, and a thin plasticdiaphragm 64 sealed across its outer end. The shoulder 60 has an outerdiameter that can be manually frictionally inserted within the surfaceof the inner diameter of sleeve 56 creating sufficient frictional forceto resist opposing force applied by fluid pressure.

[0027] A pliable sealing ring or washer 66 has a center bore 67 whichcan frictionally receive the exterior surface of fitting 58 to engagethe radial flange 52 of port 54 to seal the connection between sleeve 56and shoulder 60. The longitudinal thickness of washer 66 is less thanthe longitudinal thickness of fitting 58 so that some of the threadedsurface 62 adjacent the diaphragm 64 is exposed when the washer 66 ismounted on fitting 58 in the position described above. A nut element 68has a threaded center bore 70 which is compatible with the threadedouter surface 62 of fitting 58. When nut element 68 is tightened onthreaded portion 62, the washer 66 is in tight engagement with flange 52of port 54. The outer periphery 72 of nut element 68 has a series ofradially extending lugs 74 which frictionally detachably engage theinner surface of flange 76 of cap 78. Nut element can be tightened onwasher 66 either as positioned within cap 78, or before cap 78 and thenut element 68 are engaged. A notch 80 is located in flange 76 and isadapted to receive overflow water from tub 18 when required to do so.Notch 80 is normally in a 6 o'clock position on flange 76.

[0028] It is important to note that diaphragm 64 is of plastic material,as is fitting 58, and is preferably integrally formed with fitting 58wherein diaphragm 64 and fitting 58 are one unitary component. Diaphragm64 is a thin circular plate disk that is joined to fitting 58 by itsouter peripheral edge engaging the outer peripheral edge of the fitting58. If the two components are not molded as one unitary structure, thediaphragm 64 could be connected by fusing, hermetically sealed, or byotherwise rigidly attached” by its outer peripheral edge to the rearwardouter peripheral edges of the fitting by a suitable adhesive. No screwsor the like are either required or desired.

[0029] A second embodiment of the invention can be seen in FIG. 6. InFIG. 6 a one-piece overflow fitting 60A is seen attached to secondvertical drain pipe 34A, and a portion of the overflow fitting 60Apasses through overflow port 30.

[0030] With reference to FIGS. 7-9, shows the bathtub when the overflowfitting 60A is used. Overflow fitting 60A has an overflow pipe 62A withan inverted L-shape. The overflow pipe 62A has an elbow portion 65Awhich defines an upper end portion 66A and a lower end portion 67A. Itwill be understood that the overflow pipe 62A may be made of copper,plastic, or any other suitable material.

[0031] The upper end portion 66A has threads 68A on its outer surfaceand also has an outer end 70A. The outer end 70A defines an inlet 71A tothe upper end portion 66A of the overflow pipe 62A. The inlet 71A isadapted to fit through the bathtub overflow port 30.

[0032] The overflow fitting 60A also has a lip 74A extending radiallyoutwardly from an outer surface of the overflow pipe 62A between theelbow portion 65A and the upper end portion 66A. The lip 74A is spacedfrom the inlet 71A to engage an outer surface of the bathtub end wall 24around the bathtub overflow port 30, thereby allowing only the upper endportion 66A to pass through the overflow port 30.

[0033] A thin diaphragm 80A is sealed to the outer end 70A of the endportion 66A. The diaphragm 80A is a circular membrane and has a diameterthat is not less than the diameter of the outer end 70A of the overflowpipe 62A. In one embodiment, the diaphragm 80A is integral with theouter end 70A and is held to the outer end 70A only through having beenintegrally formed therewith. The diaphragm 80A may be hermeticallysealed to the outer end 70A. The diaphragm 80A may be composed ofplastic material, flexible rubber, or the like. The diaphragm 80A iscomposed of a material that is easily punctured or easily removable.

[0034] The overflow pipe fitting 60 further includes, a nut element 90Ahaving threads compatible with the threads 68A on the upper end portion66A of the overflow pipe 62A. The nut element 90A removably secures theoverflow pipe 62A to the bathtub 20 by compressing the end wall 24between the nut element 90A and the lip 74A. The nut element 90A may bea slip nut.

[0035] As shown in FIG. 9, the nut element 90A has a series of radiallyextending lugs 92A along the nut 90A outer periphery. These lugs 92Adetachably engage the inner surface of a cap 96A. The cap 96A serves tocover the overflow pipe fitting 60A hardware.

[0036] During installation of the overflow pipe fitting 60A, a washer94A may be placed between the upper end portion 66A of the overflow pipe62A and the nut element 90A. The washer 94A seals the overflow pipefitting 60A to the tub 20.

[0037] In operation, the drainage system comprising the ports 28 and 30,and pipes 34, 36, and 38 are installed as shown in FIG. 3. Vent pipe 40and connecting pipe 42 are also installed.

[0038] In the conventional testing procedure, the port 28 is plugged inany convenient manner. For fitting 58 with diaphragm 64 is installedinto drain pipe 34 as described above so there is no fluid access to theupper end of pipe 34 either inwardly or outwardly through overflow port30. The vent pipe is charged with water at some elevation above pipe 42so that the building inspectors can check to see if there are any leaksin the system. Having determined that there are no leaks, the water ispurged from the system. The plumber can then approach overflow port 30,(because cap 78 is not yet installed) and by using knife 86 or the like,cuts can be made in diaphragm 64 leaving a cutout portion 84 as shown inFIG. 5.

[0039] Overflow pipe fitting 60A in operation is attached to the secondvertical drain pipe 34A already plugged by the diaphragm 80A asdescribed above, so there is no fluid access to the upper end of pipe34A either inwardly or outwardly out of the overflow port 30. Thevertical vent pipe 40 is charged with water at some elevation above pipe42 so that it can be determined if there are any leaks in the system.

[0040] With reference to FIG. 10, having determined that there are noleaks, the water is purged from the system. The plumber can thenapproach overflow port 30, and by using a cutting device 10A, such as aknife of any other sharp object, cuts 102A can be made in the diaphragm80A. This can be quickly and easily done without disassembling any ofthe structure of overflow pipe fitting 60A. Any valve linkage elementsrequired may be installed through cuts 102A, and any cap or cover forthe overflow port 30 may be placed over the overflow pipe 62A endportion 66A.

[0041] It is therefore seen that this invention eliminates any need toseal shut an overflow pipe 32, 62A even after the pipe 62A has beenattached to the second vertical drain pipe 34A. The invention alsoeliminates any need to remove sealing components from the overflow port30 after the testing procedure has taken place. In addition, theinvention allows a user to install an overflow fitting 60A without usingsolvent cement. This invention also facilitates the testing procedureand reduces the time needed to seal the overflow port 30, and then toopen the diaphragm 64, 80A for possible fluid flow.

[0042] It is therefore seen this invention will achieve at least all ofits stated objectives.

I claim:
 1. An assembly for a bathtub which has a bottom and adjacentside and end walls, and an overflow port in an end wall, comprising: aone-piece overflow fitting comprising: an overflow pipe with an invertedL-shape having an elbow portion defining an upper end portion and alower end portion, the upper end portion having an outer end defining aninlet being adapted to fit through the bathtub overflow port; threads onan outer surface of the upper end portion and surrounding the inlet andnormally extending through the bathtub overflow port; a lip extendingradially outwardly from an outer surface of the overflow pipe betweenthe elbow portion and the upper end portion and being spaced from theinlet to engage an outer surface of the bathtub end wall around thebathtub overflow port; and a sealing element sealing the outer end ofthe upper end portion to close the inlet to fluid flow; a nut elementcompatible with the threads wherein the nut element has a threadedportion for threadibly mounting the nut to the upper end portion toclamp the overflow fitting to the end of the bathtub between the lip andthe nut element, and at least one lug extending radially from the nut;and a cap detachably encased to the lug and covering the nut.
 2. Anassembly for a bathtub which has a bottom and adjacent side and endwalls, and an overflow port in an end wall, and an overflow fittingcomprising: an overflow pipe with an inverted L-shape having an elbowportion defining an upper end portion and a lower end portion, the upperend portion having an outer end defining an inlet being adapted to fitthrough the bathtub overflow port; threads on an outer surface of theupper end portion and surrounding the inlet and normally extendingthrough the bathtub overflow port; a lip extending radially outwardlyfrom an outer surface of the overflow pipe between the elbow portion andthe upper end portion and being spaced from the inlet to engage an outersurface of the bathtub end wall around the bathtub overflow port; and anut element compatible with the threads on the upper end portion whereinthe nut element has a threaded portion for threadably mounting the nutto the upper end portion to clamp the overflow fitting to the end of thebathtub between the lip and the nut element, and at least one lugextending radially from the nut; and a cap detachably encasing the lugand covering the nut.
 3. The assembly of claim 1, wherein the overflowfitting is of one-piece construction.